Small Off-Road Engine Evaporative Emission Control System Certification Procedures

CP - 901

Certification And Approval Procedures for

Evaporative Emission Control Components, Technologies, and Systems

Proposed:September 27, 2002

Modified:March 25, 2003

Modified:April 2, 2003

California Air Resources BoardSeptember 27, 2002

CP-901, page 1

California Air Resources BoardSeptember 27, 2002

CP-901, page 1

CP-901

TABLE OF CONTENTS

Section Page

1. / GENERAL INFORMATION AND APPLICABILITY...... / 1
1.1 / Requirement to Comply with Applicable Codes and Regulations...... / 2
2. / PERFORMANCE STANDARDS AND SPECIFICATIONS...... / 3
2.1 / Performance Standards...... / 3
2.2 / Performance Specifications...... / 4
3. / OPTIONAL PERFORMANCE STANDARDS...... / 4
PART I / PERFORMANCE-BASED CERTIFICATION PROCESS FOR EQUIPMENT.. / 5
1. / PERFORMANCE-BASED CERTIFICATION OVERVIEW...... / 5
2. / CERTIFICATION...... / 8
2.1 / Certification Process...... / 8
2.2 / Certification Responsibilities...... / 8
2.3 / Certification Testing...... / 8
2.4 / Data Carryover and Carryacross...... / 9
3 / NEW EQUIPMENT COMPLIANCE (NEC) TESTING...... / 9
4 / IN-USE TESTING...... / 9
5 / GENERAL INSTRUCTIONS - PERFORMANCE-BASED CERTIFICATION... / 9
5.1 / Where to Submit Applications for Equipment Certification...... / 10
5.2 / Letter of Intent...... / 10
5.3 / Cover Letter...... / 10
5.4 / Equipment Labeling...... / 11
5.5 / Certification Summary Sheet ...... / 11
5.6 / Certification Database Form ...... / 11
5.7 / Emission Warranty...... / 11
5.8 / Test procedures...... / 12
5.9 / Modified Test Procedures...... / 12
5.10 / Adjustable Parameters and Anti-Tampering Devices...... / 12
5.11 / Certification Test Fuel...... / 12
5.12 / Amendments to the Application ...... / 13
5.13 / Running Changes and Field Fixes...... / 13
5.14 / Confidentiality...... / 13
6. / APPLICATION FORMAT INSTRUCTIONS...... / 14
7. / DOCUMENTATION OF CERTIFICATION...... / 14
7.1 / Executive Order...... / 14
7.2 / Summary of Certification Process...... / 14
8. / CONDITIONS OF CERTIFICATION...... / 14
8.1 / Duration of System Certification...... / 15
8.2 / Performance Monitoring...... / 15
9. / APPROVAL OF APPLICATION FOR CERTIFICATION...... / 15
PART II / DESIGN-BASED APPROACH FOR EQUIPMENT...... / 15
1. / DESIGN-BASED APPROVAL OVERVIEW...... / 15
2. / NEW AND IN-USE EQUIPMENT TESTING...... / 19
3. / GENERAL INSTRUCTIONS - DESIGN-BASED APPROVAL...... / 20
3.1 / Where To Submit Design-Based Applications...... / 20
3.2 / Application for a Letter of Compliance (LOC)...... / 21
3.3 / Engineering Description of Evaporative Emissions Control System...... / 21
3.4 / Declaration of Compatibility...... / 22
3.5 / Notification of System or Component Executive Order Holder(s)...... / 22
3.6 / Labeling Requirements...... / 22
3.7 / Application Summary Sheet...... / 23
3.8 / Application Database Form...... / 23
3.9 / Statement of Reliability...... / 23
3.10 / Materials Compatibility with Fuels...... / 24
3.11 / Refueling Compatibility of the System...... / 24
3.12 / Maintenance Requirements...... / 24
3.13 / Record Keeping Requirements...... / 24
3.14 / Warranty...... / 24
3.15 / Other Information...... / 24
4. / APPROVAL OF DESIGN-BASED APPLICATION...... / 24
PART III / APPROVAL PROCESS FOR COMPONENTS, TECHNOLOGIES
AND SYSTEMS...... / 26
1. / DESIGN-BASED APPROACH EXECUTIVE ORDER APPROVAL
OVERVIEW ...... / 26
2. / GENERAL INSTRUCTIONS – EXECUTIVE ORDER APPROVAL ...... / 29
2.1 / Where To Submit Applications for Executive Orders...... / 29
2.2 / Cover Letter...... / 29
2.3 / Application for an Executive Order...... / 30
2.4 / Engineering Description of Evaporative Emission Control Component,
Technology, or System ...... / 30
2.5 / Copies of Prior Approvals...... / 31
2.6 / Submission of Test Data...... / 31
2.7 / Component, Technology, or System Labeling ...... / 31
2.8 / Reliability...... / 32
2.9 / Component, Technology, or System Emission Factor...... / 32
2.10 / Compatibility Requirements and Information...... / 32
2.11 / Materials Compatibility with Fuels ...... / 33
2.12 / Refueling Compatibility of the System ...... / 33
2.13 / Maintenance Requirements ...... / 33
2.14 / Warranty...... / 33
2.15 / Other Information...... / 33
3 / ENGINEERING EVALUATION OF COMPONENTS, TECHNOLOGIES,
OR SYSTEMS ...... / 33
3.1 / Evaluation of a Component, Technology, or System ...... / 34
3.2 / Bench Testing of Components...... / 34
3.3 / Failure Mode Testing...... / 34
3.4 / Materials Specifications and Compatibility with Fuel Formulations...... / 34
3.5 / Installation and Maintenance Manuals...... / 34
3.6 / Durability Test Procedures and Test Results...... / 34
4 / DOCUMENTATION OF CERTIFICATION...... / 35
4.1 / Executive Order...... / 35
4.2 / Summary of Approval Process...... / 35
5 / PERFORMANCE MONITORING...... / 35
6 / APPROVAL OF APPLICATION FOR CERTIFICATION...... / 36
References / 37
Attachments
1 / SORE Evaporative Family Classification Criteria / 38
2 /

Certification Summary Sheet (Performance-Based)

3 /

Application / Approval Summary Sheet (Design-Based)

4 /

Certification Database Form (Supplementary Information)

5 /

Application Database Form (Supplementary Information)

Appendices

A / APPROVED FUEL TANKS
B / APPROVED COMPONENTS, TECHNOLOGIES, OR SYSTEMS FOR
CONTROLLING VENTED EMISSIONS
C / APPROVED FUEL LINES, FITTINGS, AND CONNECTORS
D / APPROVED CONTROL SYSTEMS
LIST OF TABLES AND FIGURES
TABLE / TITLE
1 / Proposed Performance Standards ...... / 3
2 / Optional Evaporative Emission Standards ...... / 4
3 / Optional Fuel Tank Permeation Rate Standard ...... / 5
4 / Proposed Fuel Tank Design Criteria...... / 18
5 / Proposed Evaporative Emission Control System Design Criteria
For SORE Equipment >65 cc - <225 cc ...... / 18
6 / Proposed Evaporative Emission Control System Design Criteria
For SORE Equipment 225 cc ...... / 19
7 / Required Test Procedures ...... / 31
8 / Time Requirements for the Executive Order Application Process ...... / 36
LIST OF FIGURES
FIGURE / TITLE
I / Off-Road Equipment Performance-Based Certification Process...... / 7
II / Off-Road Equipment Design-Based Approval Process...... / 17
III / Emission Control Technology Certification Process...... / 28

California Air Resources BoardApril 2, 2003

CP-901, page 1

California Environmental Protection Agency

Air Resources Board

Small Off-Road Engine Evaporative Emission Control System Certification Procedures

CP-901

Certification and Approval Procedures for

Evaporative Emission Control Components, Technologies, and Systems

A set of definitions common to all Certification and Test Procedures are in Title 13, California Code of Regulations (CCR), Section 2482 et seq.

For the purpose of this procedure, the term "ARB" refers to the California Air Resources Board, and the term "Executive Officer" refers to the ARB Executive Officer, or his or her authorized representative or designate.

1.GENERAL INFORMATION AND APPLICABILITY

This document contains three Parts that describe the procedures for evaluating and certifying equipment that use evaporative emission control systems. By definition, evaporative emission control systems are fuel system components that are designed to reduce evaporative and permeation emissions. Fuel system components may include fuel tanks, fuel lines and any or all associated fittings, mechanisms to control fuel tank venting, tethered fuel caps, and any other equipment, components, or technology necessary for the control of evaporative and permeation emissions. Part I of these Certification Procedures (procedures) describe the process to certify equipment that use small off-road engines (SORE) to performance standards. Part II of these procedures describe the process equipment manufacturers may use to receive a Letter of Compliance approving equipment that use SORE for sale in California using a design-based approach. And Part III of these procedures describes the criteria to receive an ARB Executive Order approving an evaporative emission control component, technology, or system for use under the design-based approach.

This document also contains four appendices applicable to the design-based approach that will contain approved evaporative emission control components, technologies, and systems. Appendix A shall contain the list of approved fuel tanks. Appendix B shall contain the list of approved components, technologies, or systems used in controlling vented emissions from fuel tanks. Appendix C shall contain the list of approved fuel lines, fittings, and connectors. And Appendix D shall contain the list of approved evaporative emission control systems.

The design-based approach may not be used to certify for sale in California any walk-behind lawn mower. The design-based approach allows manufacturers of components, technologies, or systems used to control evaporative emissions the option of receiving an ARB Executive Order if the component, technology, or system can show compliance with the performance requirements through appropriate testing. Upon receipt of an ARB Executive Order, the component, technology, or system would then be listed in the appropriate appendix along with compatibility guidelines and information regarding its emission characteristics provided to ARB by the applicant. Equipment manufacturers could then design, build, and certify evaporative emission control systems using these products and the information contained in the appendices. Equipment manufacturers certifying by design are not held to a specific numerical performance standard. Rather, certifying by design requires manufacturers to submit a certification application that references their evaporative emission control system components to the appropriate Executive Order(s) including a declaration of compatibility which includes a cumulative emissions calculation showing that the system is equal to or less than the applicable performance standard. Successful applicants would then be issued a Letter of Compliance (LOC) approving their equipment for sale in California.

Another option available to equipment manufacturers is certification to specific performance standards, referred to as the performance-based approach. However, walk-behind lawn mowers must be certified using the performance-based approach. This option requires manufacturers to demonstrate equipment compliance with the appropriate performance standards through testing and to submit a certification application. Successful applicants would then be issued an ARB Executive Order certifying their equipment for sale in California.

These Certification Procedures, CP-901, are proposed pursuant to Section 43824 of the California Health and Safety Code (CH&SC). The Maximum Allowable Permeation Performance Standard contained in CP-901 applies to all small off-road engines (below 25 horsepower) produced on or after January 1, 2005 and any equipment produced on or after January 1, 2005 that uses such engines. The < 225 cubic centimeters (cc) Diurnal Emissions Performance Standard contained in CP-901 applies to all Walk-Behind Mowers produced on or after January 1, 2006, and all small off-road engines > 65 cc but < 225 cc produced on or after January 1, 2007 and any equipment produced on or after January 1, 2007 that uses such engines. The 225 cc Diurnal Emissions Performance Standard contained in CP-901 applies to all small off-road engines 225 cc produced on or after January 1, 2008 and any equipment produced on or after January 1, 2008 that uses such engines. Small off-road engines are defined in Title 13, California Code of Regulations (CCR), Section 2401 et seq.

1.1Requirement to Comply with Applicable Codes and Regulations

Certification of any equipment or specific evaporative emission control component, technology, or system by the Executive Officer does not exempt the same from compliance with other applicable codes and regulations such as state and federal safety codes and regulations.

2.PERFORMANCE STANDARDS AND SPECIFICATIONS

2.1Performance Standards

A performance standard defines the minimum performance requirements for certification of any evaporative emission control system, including any or all associated components. Compliance with all applicable performance standards must be demonstrated in order to obtain certification under Part I of these Certification Procedures. Table 1 identifies the proposed performance standards and the corresponding effective dates. Equipment shall comply, throughout a minimum two year warranty period, with all applicable performance standards.

Table 1

Proposed Performance Standards

Performance Standard

/

Applicability

/

Requirement

/

Effective

Date

Maximum Allowable Permeation Emissions Performance Standard / New Equipment that use Gasoline Powered Small Off-Road Engines with Displacements
≤ 65 cc / Fuel tank permeation emissions shall not exceed 1.0 grams per square meter per day as determined by TP-901 / January 1, 2005
< 225 cc Diurnal Emissions Performance Standard / All Walk-Behind Mowers
< 225 cc / Diurnal emissions shall not exceed 1.0 grams hydrocarbons per day as determined by TP-902 and permeation emissions from a fuel tank / fuel cap assembly shall not exceed 1.0 grams per square meter per day as determined by TP-901 / January 1, 2006
< 225 cc Diurnal Emissions Performance Standard / All SORE Equipment
> 65 cc to < 225 cc / Diurnal emissions shall not exceed 1.0 grams hydrocarbons per day as determined by TP-902 and permeation emissions from a fuel tank / fuel cap assembly shall not exceed 1.0 grams per square meter per day as determined by TP-901 / January 1, 2007
225 cc Diurnal Emissions Performance Standard / All SORE Equipment
225 cc / Diurnal emissions shall not exceed 2.0 grams hydrocarbons per day as determined by TP-902 and permeation emissions from a fuel tank / fuel cap assembly shall not exceed 1.0 grams per square meter per day as determined by TP-901 / January 1, 2008

2.2Performance Specifications

A performance specification is an engineering requirement that relates to the proper operation of a specific system or component thereof. Performance specifications shall be identified in the application for certification. Compliance with the minimum level of performance specifications identified herein must be demonstrated in the application for certification and specified in the certification Executive Orders. The performance specification to which a system or component is certified shall be the minimum allowable level of performance the component is required to meet throughout a minimum two year warranty period.

3.OPTIONAL PERFORMANCE STANDARDS

Optional performance standards are emission targets that are more stringent than the normal performance standards. Manufacturers that certify equipment to these optional standards are allowed to affix a unique label to their equipment, which identifies it as low polluting. Tables 2 and 3 detail the optional performance standards.

Table 2

Optional Evaporative Emission Standards

(Grams per 24-hour diurnal test)

Calendar Year

/

Engine Group

/

Total Hydrocarbons

2006 / Walk Behind Mowers with Small off-Road Engines
> 65 cc to < 225 cc / 0.5
2007 / All Equipment with Small Off-Road Engines
> 65 cc - < 225 cc / 0.5
2008 / Equipment with Small Off-Road Engines
225 cc / 1.0

Table 3

Optional Fuel Tank Permeation Rate Standard

(Grams per meter2 per day)

Effective Date

/

Applicability

/

Requirement

Tank Permeation
January 1, 2005 / All Equipment SORE Fuel
Tanks / Fuel tank permeation emissions shall not exceed 0.5 grams per square meter per day as determined by TP- 901
PART I / PERFORMANCE-BASED CERTIFICATION PROCESS FOR EQUIPMENT
  1. PERFORMANCE-BASED CERTIFICATION OVERVIEW

For certification purposes, equipment that use small off-road engines (SORE) are grouped into three engine categories based on displacement. Handheld equipment that use spark ignited (SI) engines with displacements of less than 65 cc must be certified by the California Air Resources Board (ARB) beginning with model-year (MY) 2005 onward to be legal for sale and use in California. Walk-behind mowers with displacements in the range of greater than 65 cc to less than 225 cc must be certified beginning with model-year (MY) 2006 onward. Also, all other equipment types that utilize SI engines with displacements greater than 65 cc to less than 225 cc must be certified by ARB beginning with model-year (MY) 2007 onward. Finally, all equipment that use SI engines with displacements greater than 225 cc must be certified by ARB beginning with model-year (MY) 2008 onward. Executive Orders certifying equipment are valid for only one model-year of production. New Executive Orders in each subsequent model year must be obtained from ARB to be legal for sale and use in California. Selling equipment in California before receiving an ARB certification will subject the manufacturer and the selling dealers to ARB enforcement actions as authorized by state laws.

Equipment that use small off-road engines may be grouped into evaporative families for certification and other implementation purposes (e.g., in-use testing, and recall). An evaporative family includes equipment models that share similar fuel systems, engine designs, and emission control features such that the equipment can be expected to exhibit similar emission characteristics. Attachment 1 of these Certification Procedures defines the classification criteria and codes for determining evaporative families.

For manufacturers choosing to certify equipment that utilize small off-road engines under the performance-based option, test data that documents compliance with applicable diurnal evaporative emission standards is required. A manufacturer must test a minimum of one equipment model for every evaporative family for which certification is requested. The equipment selected for testing must be of a configuration that is expected to yield the highest evaporative emissions within an evaporative family. The test procedures used to determine compliance with applicable diurnal evaporative emission standards are described in TP-902, “Test Procedure for Determining Diurnal Evaporative Emissions from Small Off-Road Engines”.

Figure I provides a graphic overview of the certification process.

Figure I

  1. CERTIFICATION

2.1Certification Process

2.1.1Emission-Compliant Equipment: For each evaporative family, the manufacturer must test prototype equipment that has been selected and stabilized as the official certification equipment to show compliance with the appropriate evaporative emission standards. The ARB may direct the manufacturer to conduct a retest if the original test result indicates marginal (within 5% of the standard) compliance. Any anti-tampering devices that will be installed on production equipment for protection against unauthorized adjustments of emission-related adjustable parameters must be approved by ARB. The manufacturer’s format for the certification label and the location where the label is affixed to the production equipment must be approved by the ARB. The manufacturer’s emission warranty statement provided with each production engine must also be approved by ARB.

2.1.2Application for Certification: For each evaporative family, the manufacturer must submit to ARB an application for certification containing all the required information and/or test data in the ARB-specified format. The ARB is required to approve or disapprove an application within 60 days after receipt of the complete application. The normal processing time is about 4-6 weeks. To expedite the certification approval, requests for ARB approval of anti-tampering devices, labels, the emission warranty statement, and any modification to the test procedures should be submitted in advance of the application.

2.2Certification Responsibilities

Under the performance-based certification approach of Part I of these procedures, equipment manufacturers are required to obtain ARB certification for evaporative emission control systems used on equipment and are held liable for complying with all of ARB’s certification, emission warranty, New Equipment Compliance (NEC), and inuse testing and compliance requirements.

2.3Certification Testing

Prior to the time of production, an emission data equipment (a prototype piece of equipment which is expected to exhibit worst-case emissions, e.g., highest diurnal evaporative emissions) is operated according to the manufacturer’s break-in procedure to stabilize the equipment’s evaporative and permeation emissions. An emission test is then conducted using TP-902. For the evaporative family to be certified, its certification emission level, which is the diurnal test result obtained from TP-902, must not exceed the applicable evaporative emission performance standard.

2.4Data Carryover and Carryacross

Subject to ARB approval, the certification evaporative emission data may be carried over, in lieu of new tests, to subsequent evaporative families in the following model years, provided there have been no changes to the evaporative emission control system or to any evaporative emission control system component(s). Also, subject to ARB approval, the certification evaporative emission data may be carried across, in lieu of new tests, to a different evaporative family in the same model year if the manufacturer adequately demonstrates to the satisfaction of the ARB that the emission data is representative of the new evaporative family.